EXHAUST MANIFOLD INSTALLATION


  1. INSTALL STUD BOLT

    Tech Tips

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. B000MET

      Using an E8 "TORX" socket wrench, install the stud bolt to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  2. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  3. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  4. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. Install a new exhaust manifold gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) to the cylinder head sub-assembly with the 5 nuts.

    3. Install 2 new EGR cooler gaskets to the EGR pipe connector.

    4. Temporarily install the EGR pipe connector to the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly with the 4 bolts and nut.

    5. B000KESE09

      Tighten the 5 nuts in the order shown in the illustration.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }
    6. B000JFSE02
      Text in Illustration
      *a Bolt (A)
      *b Bolt (B)
      B000K70 Bolt
      B000IB9 Nut

      Tighten the 4 bolts and nut.

      Torque:
      Bolt (A) and Nut
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      Bolt (B)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL NO. 2 MANIFOLD STAY


    1. Install the No. 2 manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  6. INSTALL MANIFOLD STAY


    1. Install the manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  7. INSTALL AIR FUEL RATIO SENSOR

    Tech Tips

    Perform "Inspection After Repair" after replacing the air fuel ratio sensor Click here.


    1. B000KJHE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using SST, install the air fuel ratio sensor to the exhaust manifold.

      SST
      09224-00011
      Torque:
      Specified tightening torque
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

      Note

      If the air fuel ratio sensor has been struck or dropped, replace it.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 260 mm (10.2 in.)): 39 N*m (398 kgf*cm, 29 ft.*lbf)

    2. Connect the air fuel ratio sensor connector.

    3. Engage the 3 wire harness clamps.

  8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  10. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    1. B000IVOE03

      Using a vernier caliper, measure the free length of the 2 compression springs.

      Minimum Free Length 40.5 mm (1.59 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Temporarily install a new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

    3. B000J6AE40
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Exhaust Pipe Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

      Note


      • Be careful with the installation direction of the gasket.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipe when connecting it.

    4. Install a new exhaust pipe gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).

    5. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.

    6. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and center exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

      B000H6DE01
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *3 Exhaust Pipe Gasket
      *a Space between Flanges: 8.5 mm (0.335 in.)

    7. Connect the heated oxygen sensor connector.

  11. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.


    1. Perform Inspection After Repair after repairing an exhaust gas leak Click here.

  12. INSTALL ENGINE UNDER COVER LH


    1. Install the engine under cover LH with the 3 screws and 2 clips.

  13. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


    1. Install the front wheel opening extension pad LH with the 3 screws.

  14. INSTALL ENGINE UNDER COVER RH


    1. Install the engine under cover RH with the 3 screws and 3 clips.

  15. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


    1. Install the front wheel opening extension pad RH with the 3 screws.